Modern Manufacturing Processes

MUAMMER KOÇ, PHD, is Professor and Program Coordinator of Sustainable Development Division at College of Science and Engineering, Hamid bin Khalifa University, Qatar. His research interests include nano/micro-scale engineered surfaces, manufacturing system modeling, lightweight materials, product design and development, sustainable energy, and social and organizational efficiency.

TUĞRUL ÖZEL, PHD, is the Director of Manufacturing Automation Research Laboratory and Associate Professor in the Department of Industrial and Systems Engineering at Rutgers University, USA. His teaching and research interests include manufacturing processes, modeling and simulation, surface integrity, precision machining, metal additive manufacturing, and laser based materials processing.

Foreword xvii

List of Contributors xix

Part I Advanced Forming Processes 1

1 Advances in Stamping 3
Ilyas Kacar and Fahrettin Ozturk

1.1 Introduction 3

References 13

2 Hydroforming 15
C Hartl

2.1 Introduction 15

2.2 Fundamentals 16

2.3 Process Development and Design 33

2.4 Hydroforming Systems 37

2.5 Concluding Remarks 39

References 40

3 Incremental Sheet Forming 47
Rogelio Perez‐Santiago, Isabel Bagudanch, and Maria Luisa Garcia‐Romeu

3.1 Incremental Sheet Forming: General Overview 47

3.2 ISF Variants 49

3.3 Process Cycle 51

3.4 Materials 52

3.5 Formability in ISF 52

3.6 ISF Process Parameters 55

3.7 Accuracy 55

3.8 Simulation 57

3.9 Future Trends in ISF 58

3.10 Case Study 59

3.11 Concluding Remarks 59

References 60

4 Powder Forming 65
Rahmi Unal

4.1 Introduction 65

4.2 Reasons for Using PM Route 67

4.3 Powder Production 69

4.4 Consolidation Techniques 73

4.5 Sintering 79

4.6 Powder Injection Molding (PIM) 82

4.7 Summary and Future Work 84

References 85

5 Injection Molding at Multiscales 89
Danyang Zhao, Minjie Wang, and Donggang Yao

5.1 Introduction 89

5.2 Overview of Injection Molding 91

5.3 Injection Molding of Precision Parts 105

5.4 Injection Molding of Thin Wall Parts 109

5.5 Injection Molding of Microstructured Parts 116

5.6 Injection Molding of Microparts 124

5.7 Simulation of Injection Molding 127

5.8 Summary and Outlook 131

References 132

6 Manufacturing Techniques of Bulk Metallic Glasses 137
Mustafa Bakkal, Umut Karaguzel, and Ali T. Kuzu

6.1 Introduction 137

6.2 Mechanical Properties and Usage of Bulk Metallic Glasses 139

6.3 Rapid Quenching Methods 140

6.4 Water‐Quenching Method 141

6.5 Arc Melting Drop/Suction Casting Method 142

6.6 High‐Pressure Die Casting Method 143

6.7 Copper Mold Casting Method 144

6.8 Cap Casting Method 144

6.9 Centrifugal Casting Method 145

6.10 Metal Foaming Method 146

6.11 Concluding Remarks 147

References 147

7 Micromanufacturing 149
Omer N. Cora and Muammer Koc

7.1 Introduction 149

7.2 Classification of Micromanufacturing Processes 150

7.3 Micromanufacturing Processes 154

References 179

Part II Thermal and Energy‐assisted Manufacturing Processes 185

8 Warm Stamping 187
Fahrettin Ozturk , Serkan Toros, and Ilyas Kacar

8.1 What is Stamping? 187

8.2 Benefits and Usage Areas of Warm Stamping 187

8.3 Warm Stamping and Recent Developments 188

8.4 Effects of Temperature on Strain Hardening for Warm Stamping 194

8.5 Interrelation of Temperature and Strain Rate 196

8.6 Effect of Temperature and Deformation on Elasticity Modulus 198

8.7 Effect of Temperature on Springback 201

8.8 Effect of Temperature on Forming Limit Diagrams (FLD) 204

8.9 Analyze Techniques on Formability at Warm Stamping 205

8.10 The Effects of Lubrication 215

8.11 Future Directions 215

References 216

9 Warm Hydroforming 219
Muammer Koc, Omer N. Cora, Huseyin S. Halkacı, and Mevlut Turkoz

9.1 Introduction 219

9.2 Warm Sheet Hydroforming 220

9.3 Warm Hydromechanical Deep Drawing 230

9.4 Warm Tube Hydroforming 231

References 237

10 Hot Stamping 239
Fahrettin Ozturk , Ilyas Kacar, and Muammer Koc

10.1 Introduction 239

10.2 Process Description and Motivation 240

10.3 Why Hot Stamping? 241

10.4 Automotive Parts by Hot Stamping and Potentials 241

10.5 Advantages and Disadvantages 243

10.6 Process Description and Methods 245

10.7 Cooling for Hot Stamping 254

10.8 Process Control 255

10.9 Modeling and Analysis 255

10.10 Design and Optimization in Hot Stamping 256

10.11 FEA in Hot Stamping 257

10.12 Research and Development Trends and Needs 258

References 262

11 High‐Speed Forming (Electromagnetic, Electrohydraulic, and Explosive Forming) 265
Brad Kinsey and Yannis Korkolis

11.1 Introduction 265

11.2 Electromagnetic Forming and Magnetic Pulsed Welding 267

11.3 Electrohydraulic Forming 274

11.4 Explosive Forming 279

11.5 Emerging Technologies 282

11.6 Metrology and Measurements 284

11.7 Material Characterization 286

11.8 Modeling of High‐Speed Forming Processes 288

11.9 Summary and Future Work 291

References 292

Part III Advanced Material Removal Processes 295

12 High‐Speed Machining 297
Elisa Vazquez and Guillem Quintana

12.1 High‐Speed Machining Overview 297

12.2 High‐Speed Machining Processes and Capabilities 298

12.3 Machine Tools for High‐Speed Machining 298

12.4 Tools for High‐Speed Machining 300

12.5 High‐Speed Machining Applications and Future Trends 305

References 306

13 Hard Machining 309
Durul Ulutan and Tuğrul Ozel

13.1 Introduction 309

13.2 Mechanics of Hard Machining 312

13.3 Cutting Tools 313

13.4 Surface Quality and Integrity 316

13.5 Summary and Conclusions 320

References 320

14 Advances in Material Modeling for Manufacturing Analysis and Simulation (Deformation and Cutting Processes) 323
Elisabetta Ceretti, Claudio Giardini, and Antonio Fiorentino

14.1 Introduction on Material Characterization and Modeling 323

14.2 Material Models and Applications 324

14.3 Failure Models 327

14.4 Modeling of Contact, Friction, and Wear 331

References 347

15 Advanced Grinding 351
Taghi Tawakoli and Amir Daneshi

15.1 Introduction 351

15.2 Grinding Wheels 351

15.3 Bond Materials 353

15.4 Grinding Wheel Conditioning 354

15.5 Grinding Force and Energy 363

15.6 Thermal Damages in Grinding 363

15.7 Environmentally Friendly Grinding 364

15.8 High‐efficiency Deep Grinding (HEDG) 367

15.9 Ultrasonic‐Assisted Grinding (UAG) 367

15.10 Ultrasonic‐Assisted Dressing 371

References 373

16 Electro‐Discharge Machining (EDM) 377
Muhammad P. Jahan

16.1 Introduction 377

16.2 Principle of the EDM Process 378

16.3 EDM System Components 379

16.4 Analysis of the Pulses Used in the EDM Process 383

16.5 Brief Overview of the EDM Parameters 384

16.6 EDM Variants: Working Principles and Application Examples 385

16.7 Examples of Research Advances in EDM and Micro‐EDM 393

16.8 Research Focus Toward Micro‐ and Nano‐EDM 402

16.9 Summary 403

References 404

17 MicroMilling Operations 411
Simon S. Park, Martin B.G. Jun, and Gerardo Garcia

17.1 Introduction 411

17.2 Machine Tools for Micromilling 413

17.3 Micromilling Forces 420

17.4 Tool Tip Dynamics 427

17.5 Summary 430

References 431

18 Laser Machining 427
Dani Teixidor, Ines Ferrer, Luis Criales, and Tuğrul Ozel

18.1 Introduction 435

18.2 Laser–Material Interaction 437

18.3 Laser Processing of Materials 438

18.4 Laser‐Processing Parameters 442

18.5 Laser Drilling 445

18.6 Laser Cutting 448

18.7 Laser Milling 450

18.8 Concluding Remarks 452

References 453

19 Laser‐assisted Machining Operations 459
Eneko Ukar, Ivan Tabernero, Silvia Martinez, Aitzol Lamikiz, and Asier Fernandez

19.1 Introduction 459

19.2 Heat‐assisted Processes 460

19.3 Analysis of LAM Processes 470

19.4 Laser‐assisted Applications 474

19.5 Conclusions 477

References 478

20 Selective Laser Sintering 481
Jordi Delgado, Lidia Sereno, Karla Monroy, and Joaquim Ciurana

20.1 General Overview 481

20.2 Mechanisms 483

20.3 Process Parameters 486

20.4 Materials 490

20.5 Capabilities and Limitations 494

References 496

Index 501

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